Nanoelectronic electrochemical test device

ABSTRACT

Nanoelectronic devices for the detection and quantification of biomolecules are Provided. In certain embodiments, the devices are configured to detect and measure blood glucose levels. Also provided are methods of fabricating nanoelectronic devices for the detection of biomolecules.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit pursuant to 35 USC. §119(e) of thefollowing US Provisional Application, which is incorporated by referencein its entirety:

-   -   US Application No. 60/937,256 filed Jun. 26, 2007, entitled        “Nanoelectronic Chemical Test Device.”

This application claims priority pursuant to 35 USC. § 120 of thefollowing US Application:

-   -   U.S. application Ser. No. 11/274,747 filed Nov. 14, 2005        (published US 2007-0208243-A1) entitled “Nanoelectronic Glucose        Sensors,” which claims priority of U.S. No. 60/604,293, filed        Nov. 13, 2004, entitled “Nanotube Based Glucose Sensing,” both        of which are incorporated by reference in their entireties.

Each of the following commonly-assigned patent applications isincorporated by this reference in its entirety for all purposes:

-   -   U.S. Provisional Application No. 60/922,642 filed Apr. 10, 2007,        entitled “Ammonia Nanosensors, Environmental Control System and        Measurement Method.”    -   U.S. Provisional Applications No. 60/850,217 filed Oct. 6, 2006,        and No. 60/901,538 flied Feb. 14, 2007, each entitled        “Electrochemical nanosensors for biomolecule detection.”    -   U.S. application Ser. No. 11/636,360 filed Dec. 8, 2006,        entitled “Ammonia Nanosensors, and Environmental Control        System,” which claims priority of U.S. No. 60/748,834, filed        Dec. 9, 2005.    -   U.S. application Ser. No. 10/846,072 filed May 14, 2004,        entitled “Flexible nanotube transistors” (published US        2005-0184,641), which claims priority to U.S. No. 60/471,243        filed May 16, 2003;    -   U.S. application Ser. No. 10/656,898 filed Sep. 5, 2003 entitled        “Polymer Recognition Layers For Nanostructure Sensor Devices”        (published US 2005-0279987), which claims priority to U.S. No.        60/408,547 filed Sep. 5, 2002;    -   U.S. application Ser. No. 10/945,803 filed Sep. 20, 2004        entitled “Multiple nanoparticles electrodeposited on        nanostructures” (published 2005-0157,445), which claims priority        to U.S. No. 60/504,663 filed Sep. 18, 2003;    -   U.S. application Ser. No. 10/345,783 filed Jan. 16, 2003,        entitled “Electronic sensing of biological and chemical agents        using functionalized nanostructure” (published US 2003-0134433),        which claims priority to U.S. No. 60/349,670 filed Jan. 16,        2002; U.S. application Ser. No. 10/280,265 flied Oct. 26, 2002        entitled “Sensitivity control for nanotube sensors” (U.S. Pat.        No. 6,894,159), which claims priority to U.S. No. 60/408,412        filed Sep. 4, 2002;    -   U.S. application Ser. No. 10/177,929 filed Jun. 21, 2002        entitled “Dispersed Growth Of Nanotubes On A Substrate.”    -   U.S. patent application Ser. No. 11/063,504 filed Feb. 23, 2005        (published 20050186,333) entitled “Strip Electrode With        Conductive Nano Tube Printing,” which claims priority to U.S.        No. 60/546,762 filed Feb. 23, 2004.    -   PCT patent application No. PCTIUS2005/019,311 filed May 31, 2005        (published W02005-119,772), entitled “Coatings comprising Carbon        nanotubes” which claims priority to U.S. No. 60/576,195 filed        Jun. 2, 2004.    -   U.S. patent application Ser. No. 11/502,811, entitled        “Non-printed small volume in vitro analyze sensor and methods”        filed Aug. 10, 2006 (published 2007-0037,057), which claims        priority to U.S. No. 60/707,863 filed Aug. 12, 2005.

All of the foregoing patent applications identified above, together withany and all priority documents there of are specifically incorporatedherein, in their entirety, by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to sensors for chemical species usingnanostructured electronic devices, and methods relating to their use andmanufacture, and in particular, to devices employing nanotubes aselectronic transducers for the detection and measurement of solvatedbiomolecules or physiologic species, such as blood glucose.

2. Description of Related Art

A significant percentage of the US population suffers from diabetes(18.2 million or 6.3%). Of the 18.2 million, 13 million have beendiagnosed and of the diagnosed fraction 4 million people take insulindaily. This patient group is supported through numerous foundations andprofessional associations who provide patient care and education.

Sources report the market growth at 15% annually, driven mainly byincreased incidence of disease (obesity, diet) and increased dailymonitoring by present patients. Insulin is taken to regulate bloodglucose level. The amount of insulin taken must be titrated based onfood intake, exercise, physical condition of the user plus the currentlevel of glucose. For the 4 million who follow the insulin dosingprotocol blood glucose measurements are suggested 4 to 6 times per day.Diabetics who are not insulin dependent check their blood glucose lessfrequently, typically 1 or two times a day, to adjust oral medicationsas well as exercise and food intake. It is estimated that this resultsin about 9-10 billion glucose determinations per year worldwide.

Self-measurement of glucose is common. Measuring one's own glucose levelis typically called Self Monitoring of Blood Glucose (SMBG). Most 5MBGreadings are done on a sample of capillary blood obtained by a fingerprick. The blood is applied to a disposable sensor “strip” typically anelectrochemical sensor containing Glucose Oxidase (GOX). The sensorcurrent or voltage is read by a small electrometer referred to as aglucose meter.

An example of a popular glucose meter is shown in FIG. 1A. The stripsare contained in a cartridge. The meter automatically pushes the stripsout to collect blood. After use the user must manually remove each stripand dispose of it. Most glucose meters are battery driven and have ameasurement range of 20-600 mg/dL. Required blood volume varies between0.3 and 1 uL. Most meters are provided freely to get payback on stripusage. Disposable strips contain the actual glucose sensor. Capillaryaction is used to move the blood into the area of the sensor.

FIG. 1B shows a wearable glucose sensor. However, there is a need forglucose measurement and monitoring technology which is more convenient,cheaper, and better suited to integration into other systems, such asinvasive or implantable diagnostic or therapeutic devices.

SUMMARY OF THE INVENTION

It should be understood that one aspect of the invention herein may beset forth in one part of the description, figures, formulas, and/orexamples herein, while other aspects of the invention may be set forthin other parts of the description, figures, formulas, and/or examplesherein. Certain advantageous inventive combinations' may be taught inone part of the description, figures, formulas, and/or examples herein,and the detailed description, and the best mode of such combinations andtheir respective elements may be set forth in other parts of thedescription, figures, formulas, and/or examples herein. Therefore theinvention is to be understood broadly from this disclosure as read inits entirety, including the patent applications incorporated byreference, and including the informal claims set forth below.

Certain exemplary embodiments having aspects of the invention comprisean electronic sensor device configured for wearable monitor, whichprovides the convenience of longer term monitoring (e.g., 1 week),optionally with a disposable sensor element which provides costeffective benefits to patients. See U.S. application Ser. No. 11/274,747filed Nov. 14, 2006 entitled “Nanoelectronic Glucose Sensors”, which isincorporated by reference.

In certain embodiments, it is advantageous to make each sensor asingle-use device, the sensor being integrated into a reusablemeasurement system. Alternative embodiments may include an array withmultiple sensor elements on a chip, wherein the multiple sensors areconfigured to be used sequentially by the patient or care provider, sothat the device can provide a plurality of measurements. Theseembodiments are arranged to take advantage of the photolithographicmanufacturing technology common in the electronics industry to reducethe cost-per-measurement to a low level. Known microprocessors, outputdevices, displays and/or power sources and the like may be included inthe sensor system. See U.S. application Ser. No. 11/274,747 filed Nov.14, 2006 (published US) entitled “Nanoelectronic Glucose Sensors”, whichis incorporated by reference.

Additional exemplary embodiments having aspects of the inventioncomprise an electronic sensor device which is biocompatible andconfigured to be operated with all or a portion of the device emplacedor inserted within a patient's body. Known biocompatible materials maybereadily used to construct the sensor device. See U.S. application Ser.No. 11/274,747 filed Nov. 14, 2006 (published US) entitled“Nanoelectronic Glucose Sensors”, which is incorporated by reference.

In certain embodiments, one or more sensor devices are integrated intoor coupled to a drug delivery system, such as an implantable insulindelivery device. The electronic sensor device is configured so as tocontrol the release of one or more drugs in relation to the measuredblood concentration of one or more target species, such as thecontrolled release of insulin relative to monitored blood glucose level.See U.S. application Ser. No. 11/274,747 filed Nov. 14, 2006 (publishedUS) entitled “Nanoelectronic Glucose Sensors”, which is incorporated byreference.

Certain embodiments of a nanoelectronic patient medical monitor systemhaving aspects of the invention comprise: (a) an electronic controlprocessor disposed in a patient-portable housing; (b) an analyte fluidsampling device, comprising at least one micro-needle disposed in thepatient-portable housing, and configured to draw a sample of body fluid;(c) a plurality of nanosensors disposed in the a patient-portablehousing and in fluid communication with the analyte fluid samplingdevice; configured to transmit at least one signal in response to atarget analyte; (d) electrical measurement circuitry disposed in apatient-portable housing in communication with the electronic controlprocessor; (e) a plurality of electronically actuated valves disposed inassociation with the analyte fluid sampling device, configured toregulate the fluid communication of the analyte fluid sampling devicewith a respective nanosensor; (f) the electronic control processorfurther including a memory and code instructions configured toselectably actuate one or more of the electronically actuated valves,and to cause the electrical measurement circuitry to detect aconcentration of the target analyte using the at least one signal fromthe respective nanosensor. (g) Optionally, the nanoelectronic patientmedical monitor system may further comprise an electronicallycontrollable drug delivery system in communication with the electroniccontrol processor, configured to deliver a selected dosage of amedication in response to the detect of a target analyte in the bodyfluid sample. See U.S. application Ser. No. 11/274,747 filed Nov. 14,2006 (published US) entitled “Nanoelectronic Glucose Sensors”, which isincorporated by reference.

Additional exemplary embodiments having aspects of the inventioncomprise an insulating substrate such as a polymeric base film or strip,further comprising printed or deposited conductive material configuredas at least one electrode region on or adjacent the substrate surface,and further comprising a coating in communication with at least aportion of the electrode regions, the coating including at least afunctionalized nanostructure such as a film of carbon nanotubesfunctionalized with a metal and/or an organic material. Thefunctionalization may include a bio-selective material such as aglucose-reactive enzyme.

Certain sensor device embodiments having aspects of the inventioncomprise a substrate having a conductive layer, the conductive layercomprising a plurality of nanostructures (e.g., SWNTs, MWNTs, nanowiresand other nanoparticles of various compositions), and preferably anetwork or film of single-walled carbon nanotubes. The conductive layerpreferably has functionalization material or reacted groups, which mayinclude a quantity of platinum (Pt) nanoparticles, preferably depositedon or bound to the nanostructures, such as SWNTs. In a preferredembodiment, Pt nanoparticles are produced and bound to SWNTs in solutionor dispersion phase by reduction of a soluble Pt compound in a suitablesolvent, the Pt functionalized SWNTs then being printed, sprayed orotherwise deposited on the substrate to form the conductive layer.Preferably a detection enzyme, such as glucose oxidase (GOx) is disposeon or in association with the conductive layer. Sensor device mayincludes a counter electrode disposed adjacent the conductive layer in aspaced-apart fashion, such as on a second substrate arranged adjacentthe first substrate, the space between the counter electrode andconductive layer forming a sample cell for an analyte medium, forexample, blood (suitable containing elements may be included toimmobilize the analyte medium during sensor operation). Both counterelectrode and conductive layer may be connected to suitable measurementcircuitry to a change in an electrical property of the sensor inresponse to the presence of a target analyte. For example, glucose in ablood sample may react with GOx to form reaction products, such ashydrogen peroxide (H2O2) and gluconic acid), which in turnelectrochemically generate a current flow between counter electrode andthe conductive layer, which can be measured as an indication of glucoseconcentration.

Certain alternative sensor device embodiments having aspects of theinvention comprising a conductive layer having nanostructuresfunctionalized by binding to a conductive polymeric material, forexample a polyaniline derivative such as poly (maminobenzene sulfonicacid) or PABS. This composite material may be employed with or withoutPt nanoparticles. Certain alternative sensor architectures may beemployed in association with a conductive layer comprising ananostructure/conductive polymer composite (such as SWNT/PABS) fordetection of analytes, without departing from the spirit of theinventions. For example the sensor may be configured as a resistancesensor, an FET, a capacitance or impedance sensor, or the like, and maybe arranged as an array including a combination of these.

Additional embodiments of the invention relate to methods of fabricatingnanoelectronic sensors that involve single step deposition of the carbonnanotubes and functional biomolecules (having a functionalization thatallows interact with the analyte) on the sensor surface. The biomoleculeand carbon nanotubes interact prior to deposition, enabling single stepdeposition. The biomolecule (e.g., an enzyme, mediator, nucleic acid,antibody, etc.) retains its activity and stability after immobilizationon the electrode.

Additional aspects and embodiments of the invention are set forth in thevarious Examples in the Figures and in the Detailed Description Of TheEmbodiments

BRIEF DESCRIPTION OF DRAWINGS

The figures and drawings may be summarized as follows:

FIG. 1A shows an existing glucose sensor:

FIG. 1B shows an existing wearable glucose sensor;

FIG. 2A is a schematic cross section view of a nanostructure devicehaving aspects of the invention with a recognition layer specific to aselected analyte.

FIG. 2B is a schematic diagram of GOx functionalization of a nanotubesensor embodiment;

FIG. 3 is a plot showing the response of a sensor embodiment to glucosein water:

FIGS. 4A-4C illustrate alternative embodiments of sensors havingsolution deposited nanotube networks, wherein:

FIG. 4A shows a sensor in which a recognition layer is applied followingdeposition of nanotube film;

FIG. 4B shows a sensor in which a layer of recognition material isdeposited upon the substrate prior to application of a nanotube film 2;and

FIG. 4C shows a sensor which includes a layer of pre-functionalizednanotubes without a distinct recognition layer.

FIG. 5 illustrates an alternative embodiment of a sensor having aspectsof the invention and including nanotube networks fabricated bydeposition of a solution upon flexible substrates with pre-patternedconductor traces, including a gate dielectric and gate electrode.

FIG. 6 shows an exemplary embodiment of a sensor device 50 havingaspects of the invention and including a nanotube networks fabricated bydeposition of a solution of pre-functionalized nanotubes upon asubstrate.

FIG. 7 shows architecture of a sensor device embodiment having aspectsof the invention for detection and measurement of biomolecular speciessuch as polynucleotides, proteins, polysaccharides and the like.

FIG. 8 shows an example of square wave voltammetry (SWV) response of ananotube electrode such as shown in FIG. 7, illustrating the effect of aferrocyanide/ferricyanide redox couple.

FIG. 9 shows an example of differentiating cyclic voltagrams (CV)illustrating the response of a nanotube electrode such as shown in FIG.7 with a ferrocyanide/ferricyanide redox couple.

FIG. 10 (Views A-C) illustrate an exemplary electrochemical sensorconfigured as a blood test strip.

FIG. 11 is a plot showing the response of a electrochemical sensorembodiment functionalized with SWNT-PABS.

FIGS. 12A-12B illustrate an exemplary electrochemical test strip havinga CNT working electrode and a vented capillary path.

FIG. 13 is a plot showing cyclic voltammmetry data for strips ha ingCNT-functionalized conductive carbon layer and strips ha ing aconductive carbon layer without CNTs.

FIG. 14A is a plot showing glucose detection in blood spiked withvarious concentrations of glucose using glucose oxidase enzyme andpotassium ferricyanide mediator with a CNTs modified electrode.

FIG. 14B shows glucose detection in PBS spiked with variousconcentrations of glucose using glucose oxidase enzyme and potassiumferricyanide mediator with a CNTs modified electrode.

FIGS. 15A-15B are plots showing responses of electrochemical sensorembodiments functionalized with antibodies.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The making, functionalization and use of nanostructured chemosensor andbiosensor devices is described in considerable detail in the patentapplications incorporated by reference above.

Example A NTFET Glucose Sensor

A number of preferred sensor embodiments employ nanostructures, such asnanotubes. FIG. 2A. shows an electronic sensing device 10 for detectinga liquid or gaseous analyte 11, comprising a nanostructure sensor 12.Device 12 comprises a substrate 1, and a conducting channel or layer 2including nanostructured material disposed upon a substrate 1.

The nanostructured material may contact the substrate as shown, or inthe alternative, may be spaced a distance away from the substrate, withor without a layer of intervening material. As used herein, a“nanostructured material” includes any object or objects which has atleast one dimension smaller than about 100 nm and comprises at least onesheet of crystalline material with graphite-like chemical bands.Examples include, but are not limited to, single-walled nanotubes,double-walled nanotubes, multi-walled nanotubes, and “nanoanions.”Chemical constituents of the crystalline material include, but are notlimited to, carbon, boron nitride, molybdenum disulfide, and tungstendisulfide. Preferably a nanotube is a carbon nanotube, and morepreferably it is a single-walled carbon nanotube.

In an embodiment of the invention, conducting channel 2 may comprise oneor more carbon nanotubes. For example, conducting channel 2 may comprisea plurality of nanotubes forming an interconnecting mesh, film ornetwork Typically, a “nanotube network” is a film of nanotubes disposedon a substrate in a defined area A film of nanotubes comprises at leastone nanotube disposed on a substrate in such a way that the nanotube issubstantially parallel to the substrate. The film may comprise manynanotubes oriented generally parallel to each other. Alternatively, thefilm may comprise many nanotubes, each oriented substantially randomlywith respect to adjacent nanotubes, or the nanotubes may be orientedsubstantially perpendicular to the substrate, e.g., as in a “nano-turf”configuration.

The number of nanotubes in as area of substrate is referred to as thedensity of a network. Preferably, the film comprises many nanotubesoriented substantially randomly, with the density high enough thatelectric current may pass through the network from one side of thedefined area to the other side. Methods for disposing a high density ofnanotubes are disclosed in U.S. application Ser. No. 10/177,929, filedJun. 21, 2002 by Gabriel et al. (equivalent to W02004-040,671), which isincorporated by reference.

Solvent/suspension Deposition Nanoparticle Network. Alternatively, ananotube network may be deposited on a device substrate by spraydeposition and the like. Such methods as spin coating, spray deposition,dip coating and ink jet printing may be employed to deposit the solutionor suspension of nanostructures, such as nanotubes.

For example, single wall carbon nanotubes (SWNTs) and/or othernanoparticles may be suspended in a suitable fluid solvent, and sprayed,printed or otherwise deposited in a substrate. The SWNTs or othernanoparticles may optionally have additional functionalization groups,purification and/or other pre-deposition processing. For example SWNTsfunctionalized with poly m-aminobenzene sulfonic acid (PABS) showhydrophilic properties and may be dispersed in aqueous solutions.

One or more conductive traces or electrodes may be deposited afterdeposition, or alternatively, the substrate may include pre-patternedelectrodes or traces exposed • on the substrate surface. Similarly,alternative embodiments may have a gate electrode and a source electrodesupported on a single substrate. The substrate may include a flat,sheet-like portion, although one skilled in the art will appreciate thatgeometric variations of substrate configurations (rods, tubes or thelike) may be employed without departing from the spirit of theinventions.

The density of a network of nanotubes (or other nanostructure elements)maybe adjusted to achieve a selected conductivity in an electricallycontinuous network via interconnections between adjacent nanotubes(e.g., a CNT film of density close to but greater than the percolationlimit). For example, this may be achieved through controlled CVDconditions, e.g., catalyst particle density, deposition environment,duration, or the like (see Ser. No. 10/177,929, filed Jun. 21, 2002).

In another example, density of a network of nanotubes may be controlledby flow through a filter membrane. In such embodiments, a micro-porousfilter, membrane or substrate may be employed in deposition of ananotube (or other nanoparticle) network channel from suspension orsolution. A porous substrate can accelerate deposition by removingsolvent so as to minimize “clumping”, anal can assist in controllingdeposition density. The deposition may be carved out by capillaryabsorption, or using suction or vacuum deposition across the poroussubstrate or membrane, as described in the above referenced applicationSer. No. 10/846,072 (e.g., see description of FIG. 3 and Example B ofthat application); in U.S. Provisional Application No. 60/639,954 filedDec. 28, 2004 entitled ‘Nanotube Network On-Top Architecture ForBiosensor’; and in L. Hu et al., Percolation in Transparent andConducting Carbon Nanotube Networks, Nano Letters (2004), 4, 12,2513-17, each of which application and publication is incorporatedherein by reference. The network thus formed may be separated from thedeposition membrane using a method such as membrane dissolution ortransfer bonding, and included in a sensor device structure as aconducting channel (e.g., disposed on a device substrate, contact grid,or the like).

In a spray-deposition example, multiple light, uniform spray steps maybe performed (e.g., with drying and resistance testing between spraysteps) until the network sheet resistance reaches a target value(implying a target network density and conductivity). In one example,P2-SWNTs produced by Carbon Solutions, Inc of Riverside, Calif. werespray-deposited on a portion of a PET sheet substrate with pre-patternedtraces until a sheet resistance about 1 kS1 was reached.

Dispersed networks of nanotubes and methods of formation are furtherdescribed in U.S. application Ser. No. 11/636,360 filed Dec. 8, 2006(published US), U.S. application Ser. No. 11/274,747 filed Nov. 14, 2006(published US); and U.S. application Ser. No. 10/846,072 filed May 14,2004 (published US 2005-0184,641), each of which is incorporated byreference.

Substrates may be flat objects that are electrically insulating.Substrates have a chemical composition, of which examples include, butare not limited to, silicon oxide, silicon nitride, aluminum bride,polyimide, and polycarbonate. Preferably the substrate is a siliconoxide film on a silicon chip.

One or more conductive elements or contacts 3 a, 3 b may be disposedover the substrate and electrically connected to conducting channel 2.Elements 3 a, 3 b may comprise metal electrodes in direct contact withconducting channel 2. In the alternative, a conductive orsemi-conducting material (not shown) may be interposed between contacts3; 3 b and conducting channel 2. Contacts 3 a, 3 b may comprise a sourceelectrode S and a drain electrode D upon application of a selectedand/or controllable source-drain voltage Vsd (note that the voltageand/or polarity of source relative to drain may be variable, e.g.,current may be DC, AC and/or pulsed, and the like). In such case, thecontacts are arranged so that the nanotube network comprises at leastone conductive path between at least a pair of conductors.

Alternatively, a contact or electrode may be employed to provide acharge to the channel 2 relative to a second electrode, such that thereis an electrical capacitance between the second electrode and thechannel 2. The second electrode may be a gate electrode, a discretebottom electrode (e.g. embedded in, under, and/or doped within thesubstrate), a top gate electrode, a liquid medium electrode, and thelike. In another exemplary preferred embodiment, the gate electrode is aconducting element in contact with a conducting liquid, said liquidbeing in contact with the nanotube network. In other embodiments, thedevice includes a counter electrode, reference electrode and/orpseudo-reference electrode.

In one exemplary preferred embodiment, the gate electrode is aconducting plane within the substrate beneath the silicon oxide.Examples of such nanotube electronic devices are provided, among otherplaces, in application Ser. Nos. 10/656,898, filed Sep. 5, 2003 (US2005-0279987) and 10/704,066, filed Nov. 7, 2003 (US 2004-0132,070),both of which are incorporated by reference. FIG. 2A, the device 10 mayoperate as a gate-controlled field effect transistor via the effect ofgate electrode 4. In this example, the gate 4 comprises a base portionof the substrate, such as doped-silicon wafer material isolated fromcontacts 3 a, 3 b and channel 2 by dielectric 5, so as to permit acapacitance to be created by an applied gate voltage Vg. For example,the substrate 1 may comprise a silicon back gate 4, isolated by adielectric layer 5 of SiO2. Such devices are generally referred toherein as nanotube field effect transistors (NTFET).

Embodiments of an electronic sensor device having aspects of theinvention may include an electrical circuit configured to measure one ormore properties of the nanotube sensor, such as measuring an electricalproperty via the conducting elements. For example, a conventional powersource may supply a source drain voltage Vsd between contacts 3 a, 3 b.Measurements via the sensor device 10 may be carried out by circuitryrepresented schematically by meter 6 connected between contacts 3 a, 3b. In embodiments including a gate electrode 4, a conventional powersource may be connected to provide a selected and/or controllable gatevoltage Vg. Device 10 may include one or more electrical supplies and/ora signal control and processing unit (not shown) as known in the art, incommunication with the sensor 12.

Any suitable electrical property may provide the basis for sensorsensitivity, for example, electrical resistance, electrical conductance,current, voltage, capacitance, transistor on current, transistor offcurrent, and/or transistor threshold voltage. Alternatively, sensitivitymay be based. on measurements including a combination, relationship,pattern and/or ratios of properties and/or the variation of one or moreproperties over time. For example, the capacitance or impedance of thenanostructures relative to a gate or counter electrode. Similarly, abreakdown voltage or electron emission voltage and/or current may bemeasured between nanostructures and a reference electrode.

In certain embodiments, a transistor sensor may be controllably scannedthrough a selected range of gate voltages, the voltages compared tocorresponding measured sensor current flow (generally referred to hereinas an I-Vg curve or scan). Such an I-Vg scan may be through any selectedgate voltage range and at one or more selected source-drain potentials.The Vg range is typically selected from at least device “on” voltagethrough at least the device “off” voltage. The scan can be either withincreasing Vg, decreasing Vg, or both, and may be cycled +− at anyselected frequency.

From such measurements, and from derived properties such as hysteresis,time constants, phase shifts, and/or scan rate/frequency dependence, andthe like, correlations may be determined with target detection and/orconcentration and the like. The electronic sensor device may includeand/or be coupled with a suitable microprocessor or other computerdevice of known design, which may be suitably programmed to carry outthe measurement methods and analyze the resultant signals. Those skilledin the art will appreciate that other electrical and/or magneticproperties, and the like may also be measured as a basis forsensitivity. Accordingly, this list is not meant to be restrictive ofthe types of device properties that can be measured.

In certain embodiments, sensor 12 may further comprise a layer ofinhibiting or passivation material 6 covering regions adjacent to theconnections between the conductive elements 3 a, 3 b and conductingchannel 2. The inhibiting material may be impermeable to at least onechemical species, such as the analyte 11. The inhibiting material maycomprise a passivation material as known in the art, such as silicondioxide, aluminum oxide, silicon nitride, and the like. Further detailsconcerning the use of inhibiting materials in a NTFET are described inprior application Ser. No. 10/280,265, filed Oct. 26, 2002 (US2004-0043527), which is incorporated by reference herein.

The conducting channel 2 (e.g., a carbon nanotube layer) is typicallyfunctionalized to produce a sensitivity to one or more target analytes11. Although nanoparticles such as carbon nanotubes may respond to atarget analyze through charge transfer or other interaction between thedevice and the analyte, more generally a specific sensitivity can beachieved by employing recognition material 7 that induces a measurablechange the device characteristics upon interaction with a targetanalyze. Typically, the sensor functionalization layer 7 is selected fora specific application. The analyte may produce the measurable change byelectron transfer, and/or may influence local environment properties,such as pH and the like, so as to indirectly change devicecharacteristics. Alternatively or additionally, the recognition materialmay induce electrically-measurable mechanical stresses or shape changesin the conducting channel 2 upon interaction with a target analyte.

In a typical embodiment having aspects of the invention, the sensitivityis produced and/or regulated by the association of the nanotube layer 2with a functionalization material, e.g. disposed as a functionalizationlayer 7 adjacent channel 2. The functionalization layer 7 may be of acomposition selected to provide a desired sensitivity to one or moretarget species or analytes. The functionalization material may bedisposed on one or more discrete portions of the device, such as on allor a portion of the channel 2, or alternatively may be dispersed overthe sensor 12, such as on contacts 3 and/or exposed substrate 1.

Optionally device 10 may comprise a plurality of sensors 12 disposed ina pattern or affray, as described in U.S. patent application Ser. No.10/388,701 filed Mar. 14, 2003 entitled “Modification Of Selectivity ForSensing For Nanostructure Device Arrays” (now published as US2003-0175161). Each device in the array can be functionalized withidentical or different functionalization. Identical device in an arraycan be useful in order to multiplex the measurement to improve thesignal/noise ratio or increase the robustness of the device by makingredundancy.

The above described sensor embodiments, such as a preferred embodimentof a carbon nanotube network transistor, may be treated or engaged withmany alternative functionalization materials, probes, moleculartransducers, coatings and the like.

In one example of a glucose sensor, the network is functionalized usingthe enzyme glucose oxidase (GOx), so as to provide glucose-specificsensitivity. FIG. 2B diagrammatically illustrates the functionalization.In one preferred example, the GOx (or an alternative biomolecule probe)may be bonded to a linker molecule, such as pyrene, polymer or the like.(See patent application Ser. No. 10/345,783 incorporated by referenceabove).

The linker molecule, in turn, is selected to have properties which causeit to associate with the lattice of the carbon nanotube, such as bynon-covalent pi-pi stacking between the graphitic nanotube lattice andthe flat ring pyrene structure. (see Besteman, et al., Enzyme CoatedCarbon Nanotubes As Single Molecule Biosensors, Nano Letters, 2003 Vol.3, No. 6, 727-730) Such a functionalization structure is referred to asa molecular transducer.

In operation of the sensor, the immobilized GOx reacts with glucosepresented in the contacting medium so as to alter the electricalproperties of the nanotube device. FIG. 3 shows a plot of the responseof a NT sensor device (in this example the device is a NTFET generallyas shown in FIG. 2A) with Vgate=0). Initially, in a water medium withoutglucose, the conductance is about 1200-1250 muS. Upon injection of aglucose sample (at arrow) the conductance rises to a stable level ofabout 1450 muS. There is an very brief transient at injection, which isbelieved to be an artifact of the injection process (brief exposure toair). The change in conductance may be correlated with the concentrationof glucose. The response time and transient may be controlled byappropriate sample presentation, such as by rapid mixing to equilibriumconcentration in contact with functionalized nanotube network. Theresponse of the NT sensor toward an increased conductance is indicativeof the effect of the biochemical environment (GOx reacting with aqueousglucose solution) on the conductance of the nanotube network channel 2as measured between source 3 a and drain 3 b.

Alternative enzymes may be employed for chemodetection and biodetectionin a manner similar to that described above. For example, an alternativeglucose sensor system embodiment is functionalized using the enzymemethane reductase, so as to provide sensitivity to methane for methanemeasurement and detection. In addition other reactive or receptivebiomolecules can target particular species, such as direct or indirectantibody reactions. For example, the probe may be a commerciallyavailable anti-HIV antibody which is reactive to target components ofthe HIV virus in a patient sample. Alternatively the probe may be acommercially available HIV antigen component, reactive to target humananti-HIV antibodies (from patient sample).

One of ordinary skill in the art can readily identify useful knownprobe-target combinations of biomolecules, such as enzymes and theirsubstrates, antibodies and their specific antigens, and the like, whichmay be used to produce the molecular transducers for alternativeembodiments, without departing from the spirit of the invention andwithout undue experimentation. Note that the sensor arrays describedabove may be included in system embodiments sensitive to multipletargets. Alternatively, the arrays may providing multiple differentlyfunctionalized sensors for the same target species, to enhanceselectivity, sensitivity, dynamic range, and the like.

Example B Sensor with Solution Deposited Nanotube Network

FIG. 4A is a diagram of an alternative exemplary embodiment of ananosensor 20 having aspects to the invention, including a network ofcarbon nanotubes. Certain elements are generally similar to those ofFIG. 2A, and the same reference numbers are indicated.

Sensor 20 comprises a substrate 9, which preferably comprises a flexiblesheet-like material such a polyester polymer (e.g., PET sheet). One ormore electrodes (3 a and 3 b are shown) are arranged on the substrate.The electrode may comprise a metal, or may be’ formed from a paste orink-like composition, such as carbon, graphite, conductive polymer,metallic ink compositions, and the like.

A nanostructure layer 2 (in this example a film including SWNTs) isdeposited contacting the electrodes 3 a (and 3 b in this example). Anoptional functionalization or recognition layer 7 may be included inassociation with the layer 2, for example applied following depositionof SWNT film 2. An optional passivation, protective or inhibiting layer8 may cover electrodes 3 and all or a portion of layers 2 and 7.

In a preferred embodiment, substrate 9 is a flexible sheet havingpre-pattered printed electrodes 3, permitting simplicity and costreduction. Preferably the nanostructure layer 2 is formed by spraying orotherwise coating the patterned substrate with an liquid suspension ofnanotubes. For example, SWNTs or MWNTs may be conveniently dispersed inaqueous suspension at a desired concentration, particularly wherefunctionalization treatment of the SWNTs assist in making the nanotubeshydrophilic (see EXAMPLES D-F below). Alternatively organic solvents maylikewise be used to disperse and apply the nanotube film 2. See U.S.patent Ser. No. 10/846,072; and L. Hu et al., Percolation in Transparentand conducting Carbon Nanotube Networks, Nano Letters (2004), 4, 12,2513-17, each of which is incorporated herein by reference.

In certain embodiments, recognition or detection material is deposited,reacted or bound to the nanotubes (or alternative nanostructures) priorto deposition of layer 2. Depending on the selected detection chemistryand analyte target, such pre-functionalization may eliminate the needfor any distinct recognition layer 7.

Alternative nanotube dispersion techniques may also be employed, see forexample, U.S. patent application Ser. No. 10/846,072 entitled “FlexibleNanotube Transistors”; and L. Hu et al., Percolation in Transparent andConducting Carbon Nanotube Networks, Nano Letters (2004), 4, 12,2513-17, each of which application and publication is incorporatedherein by reference.

The nanostructure layer 2 may be deposited stepwise, with intermediatedrying, to permit the density and conductivity of the layer 2 to beaccurately controlled, such as by probe-testing the layer resistance orconductance between deposition steps, until a selected layerconductivity or resistance is achieved.

In the example of FIG. 4A, the electrodes 3 a, 3 b are shown depositedupon substrate 9 beneath the SWNT film 2, as this advantageously permitsthe use of substrates having pre-printed or pre-patterned electrodematerial, which permits substantial costs savings in volume production.However, other electrode configurations are possible without departingfrom the spirit of the invention.

In the example shown in FIG. 4B, a layer of recognition material 7′ isdeposited upon the substrate or to application of the nanotube film 2,and is disposed underneath, film 2. In either of the examples of FIGS.4A and 4B, a recognition material may penetrate the nanotube network 2so as to be incorporated as a mixture.

In certain embodiments, recognition or detection material is deposited,reacted or bound to the nanotubes (or alternative nanostructures) priorto deposition of layer 2. Depending on the selected detection chemistryand analyte target, such pre-functionalization may eliminate the needfor any distinct recognition layer 7. In the example shown in FIG. 4C, alayer of pre-functionalized nanotubes 12 is deposited upon thesubstrate, without arty separate application of a recognition orfunctionalization material.

The nanostructure layer 2 may be deposited stepwise, with intermediatedrying, to permit the density and conductivity of the layer 2 to beaccurately controlled, such as by probe-testing the layer resistance orconductance between deposition steps, until a selected layerconductivity or resistance is achieved.

Suitable measurement circuitry is included in communication withelectrodes 3 a and 3 b (and any optional additional electrodes), hererepresented by meter 6 and source-drain power source W.

FIG. 5 shows a NTFET alternative sensor 60 having space-apart source anddrain traces 3 a and 3 b disposed on substrate 9. An additionalintermediate trace 14 is coated with a thin layer of dielectric orinsulating material 15 (organic film or inorganic deposit) prior todeposition of nanotube layer 12, so as to form a gate electrode(permitting operation as a transistor).

In one example, dielectric material 15 is a ALD layer comprising Al2O3,ZrO2, or the like. Material 15 may be only a few nanometer in thickness(e.g., between about 10 and about 100 nm). Further description of ALDmethods may by found in P. Chen, et al, “Atomic Layer Deposition toFine-Tune the Surface Properties and Diameters of Fabricated Nanopores”,Nano Lett (June 2004) Vol. 4, No. 7, pp 1333-37; D. Farmer et al,“Atomic Layer Deposition on Suspended Single-Walled Carbon Nanotubes viaGas-Phase Noncovalent Functionalization”, Nano Lett (March 2006) Vol. 6,No. 4, pp 699-703; and M. Groner et al, “Gas diffusion barriers onpolymers using A1203 atomic layer deposition”, Appl. Phys. Lett. (2006)Vol. 88, pp 051907-1 to -3; which publications are incorporated byreference.

Example C Sensor Having a Pre-Functionalized Nanotube Network

Sensor fabrication. FIG. 6 shows an exemplary embodiment of a sensordevice 50 having aspects of the invention and including a nanotubenetworks fabricated by deposition of a solution or dispersion ofnanotubes upon a substrate 9 to form a nanotube film 12. In an exemplaryembodiment shown in FIG. 6, the nanotubes (or other nanostructures) aredispersed in a volatile solvent which evaporates following deposition toleave the nanotubes configured as an open network 12.

Although electrical contacts may be deposited or applied subsequent tonanotube deposition, it is convenient and advantageous to patterndesired electrode or contact material 3 upon the substrate 9 prior tonanotube deposition (four contacts 3 a-3 d are shown). For example,substrates (e.g., polymer sheets such as PET, polystyrene, polycarbonateand the like) are commercially made having printable conductor materialapplied in a selected pattern (e.g., carbon, silver, gold, silver/silverchloride, mixtures and the like). A suitable flexible PET substrateswith a pattern of printed conductive carbon traces may purchased fromConductive Technologies, Inc., of York, Pa., for example, a flexible PETsubstrate with screen-printed carbon paste electrodes, with spacingbetween the conductive traces of about 1 mm. A plurality of devices mayconveniently be fabricated on a sheet of substrate material, and maysubsequently be partitioned and packaged as desired, either as singlesensor devices, or as arrays of sensors, and the no.

In an exemplary embodiment having aspects of the invention, the nanotubenetwork was formed from SWNTs which were functionalized by covalentlybonded poly-(m-aminobenzene sulfonic acid (“PAWS”). C′-bon nanotubes,preferably SWNTs, may be reacted and treated with PAWS (compositereferred to as “ST-PAWS”) by the methods as described in B Mao et al,“Synthesis and Properties of a Water-Soluble Single-Walled CarbonNanotube Poly-(m-aminobenzene sulfonic acid) Graft Copolymer”, Adv FunctMater (2004) Vol 14, No 1 pp 71-76, which article is incorporated byreference. A suitable nanotube composite material (“SWNT-PABS”) may beobtained from Carbon Solutions, Inc. of Riverside, Calif. in the form ofa dry powder.

A variety of alternative functionalization species may be included, suchas conductive polymeric materials, polyaniline (PANT), polypyrrole,polyaniline derivatives, and the alternative materials described abovein TABLE 3 of U.S. application Ser. No. 11/636,360 filed Dec. 8, 2006(published U.S. Ser. No. ______), which is incorporated by reference.

See, for example, the electrochemical treatments described in T Zhang etal, “Nanonose: Electrochemically Functionalized Single-Walled CarbonNanotube Gas Sensor Array”, Proc. 208th Meeting of ElectrochemicalSociety (Los Angeles, Calif. Oct. 16-21, 2005), which is incorporated.by reference.

A suitable aqueous deposition solution may be made by suspendingSWNT-PABS powder in water (preferably at a concentration of about 1mg/mL.), and ultrasonication may be employed to assist in making ahomogeneous dispersion. The carbon nanotube dispersion may be sprayedwith an air brush to coat the substrate.

Preferably the deposition is done in several light coating as withintermediate drying (for example on a hotplate with the temperature ofabout 55 to 75 degree C.). The film resistance may be measured betweensteps until the selected resistance is obtained (the measurement may bebetween printed traces, or may be by pin probes on the network coating.For example, the deposition may be continued until resistance with ahalf-inch pin probe spacing is about 15 K Ohm.

Example D CNT Electrochemical Sensor Exemplary Sensor Devices.

FIG. 7 shows schematic architecture of a sensor device embodiment havingaspects of the invention for detection and measurement of biomolecularspecies, as described in further detail in U.S. Provisional ApplicationsNo. 60/850,217 filed Oct. 6, 2005, and No. 60/901,538 filed Feb. 14,2007, each entitled “Electrochemical nanosensors for biomoleculedetection”, which are incorporated by reference.

In a particular example, device 10 may be employed detection of amolecular species of biological origin. The device 10 comprises a sensorsubstrate 12 (e.g., comprising PET, polycarbonate, flexible polymers, orthe like) having a reaction or sensor tip portion of its surface 20 onwhich an interconnecting carbon nanotube (CNT) network 14 is disposed.In the example of FIG. 1, a conductive trace or drain 15 electricallycommunicates with the network 14 (e.g., silver ink may be deposited onthe substrate 12 so as to contact a portion of the network 14).

Device 10 includes a well or container 17 holding buffer or fluid media19 in which both sensor tip 20 and a gate electrode 18 are immersed. Incertain embodiments, gate electrode 18 may include a referenceelectrode, such as a Ag/AgCl reference electrode, saturated calomelelectrode, or the like. One skilled in the art will appreciate thatcontainer 17 may comprise one or more microfluidic elements,capillaries, sampling devices, incubators, and the like, withoutdeparting from the spirit of the invention.

An encapsulation material 16 (e.g., polymers such as epoxy, Al₂O₃,Si₄N₃, SiO₂, ALD layers, and the like) may be deposited so as to isolateportions of the device from the medium or buffer 19, while not coveringat least a portion of the CNT network 14.

With reference to encapsulation material 16 and to other encapsulationlayers, dielectric layers and/or isolation layers or multi-layerstructures included in alternative embodiments having aspects of theinvention described herein, it may be advantageous to produce layersthat are extremely flan and uniform, while at the same time avoidingpores, shadowing or other discontinuities/irregularities in the coating.It may also be desirable in certain elements to avoid damage tounderlying elements, such as carbon nanotube networks. Atomic layerdeposition methods provide alternative approaches to producing a layeror coating having the desirable qualities, and may be employed todeposit a layer of an oxide, nitride or other compound, or combinationsor multiple layers of these. Alternative methods may be used, such asthermal and e-beam evaporation. Additional process elements may beincluded to improve ‘coating properties, such as rotating and/or tiltinga substrate during evaporation. Further description of ALD methods mayby found in P. Chen, et al, “Atomic Layer Deposition to Fine-Tune theSurface Properties and Diameters of Fabricated Nanopores”, Nano Lett(June 2004) Vol. 4, No. 7, pp 1333-37; D. Farmer et al, “Atomic LayerDeposition on Suspended Single-Walled Carbon Nanotubes via Gas-PhaseNoncovalent Functionalization”, Nano Lett (March 2006) Vol. 6, No. 4, pp699-703; and M. Groner et al, “Gas diffusion barriers on polymers usingAl2O3 atomic layer deposition”, Appl. Phys. Lett. (2006} Vol. 88, pp051907-1; which publications are incorporated by reference.

Drain 15 and gate 18 are connected to suitable measurement circuitry 13,which may comprise one or more of a number of devices conventionallyused for signal measurement, recordation, display, power supply, signalprocessing and/or logic operations, and the like, as described fartherherein. Additional or substitute electrodes may also be included indevice 10, such as counter electrodes, reference electrodes and thelike, such as Ag/AgCl reference electrodes described herein.

A CNT network may be made by methods described above with respect toEXAMPLES A-C, such as by CVD formation of CNT from catalystnanoparticles (see Ser. No. 10/177,929), by spray deposition, or thelike.

One or more conductive traces or electrodes may be deposited afterdeposition, or alternatively, the substrate may include pre-patternedelectrodes or traces exposed on the substrate surface. Similarly,alternative embodiments may have a gate electrode and a source electrodesupported on a single substrate. The substrate may include a flat,sheet-like portion, although one skilled in the art will appreciate thatgeometric variations of substrate configurations (rods, tubes or thelike) may be employed without departing from the spirit of theinventions.

Analyte-specific functionalization may be included on or adjacent tonetwork 14, such as redox enzymes capable of producing an electroactivespecies when bound to an analyte as a substrate (e.g., glucose oxidaseactive on a glucose substrate). Alternative functionalization includesanalyte-specific receptors or binding probes, such as antibodies,oligonucleotides, and the like.

Redox Couple Species to Enhance Electron Transfer.

FIG. 8 shows an example of square wave voltammetry (SWV) response of ananotube electrode such as shown in FIG. 7 in buffer alone (lowercurve), as compared with the response in a buffer with added redoxcouple (upper curve). In this example, the redox couple includes 10 mMsolution of Fe(CN)₆ ^(3−/4−) added to AP buffer. As it can be seen fromFIG. 2, the ferrocyanide/ferricyanide redox couple produces more than100 fold increase of electron transfer between solution and the deviceas indicated by square voltammetry method. The device shows purelyelectrochemically capacitive behavior in buffer alone, but converts to‘resistor’ in the presence of ferrocyanide/ferricyanide redox couple.Square voltammetry methods are further described in A J Bard and LFaulkner, Electrochemical Methods: Fundamentals and Applications (Wileyand Sons, New York, 2001); and J Wang, Analytical Electrochemistry(Wiley and Sons, New York, 2000), which publications are incorporated byreference.

As shown in FIG. 9, further amplification of the dynamic range can beachieved by differentiating cyclic voltagrams (CV): The maximum of thederivative of the totally reversible system is close to thehalf-potential value, which happens to be around −230 mV versus Ag/AgCreference electrode. With this approach the response is extended tothree orders of magnitude, comparing the response with buffer alone(lower curve) versus buffer with ferrocyanide/ferricyanide redox couple(upper curve).

In addition or in substitution to the ferrocyanide/ferricyanide redoxcouple described, alternative redox couple species may be employedwithout departing from the spirit of the invention.

Example E Printed Substrate Sensor Device

An alternative exemplary embodiment of an electrochemical sensor includesingle walled carbon nanotubes (SWNTs) having aspects to the invention,configured in one example as a test strip for detection of glucose.

FIG. 10, Views A-C illustrate an exemplary electrochemical sensor 40, inthis example configured as a blood test strip. A first substrate 41 a(View A) and a second substrate 41 b (View B) comprise a flexible sheetmaterial such as PET polymer. A counter electrode 42 (preferablycomprising a conductive ink) is printed, screen printed, shadow masked,or otherwise deposited on substrate 41 a. Additional optional electrodessuch reference electrode 43 and/or calibration electrode 44 may bedeposited adjacent counter electrode 42. A conductive nanostructuredfilm electrode 45 is deposited on substrate 41 b. Film 45 may beprinted, or may be spray deposited in the manner described with respectto the sensor 20 of FIG. 4A.

Substrates 41 a and 41 b are preferably shaped so that they may becounter-posed and attached to one-another, such as by adhesive layer 46to form a multilayer assembly (View A+B). Adhesive layer 46 may serve asan insulator to electrically isolate the counter electrode 42 (and also43-44) from nanotube film 45 in the assembly, and the adhesive may alsoserve as a space to maintain a space between the substrate layers 41a-41 b (best seen in cross-section View C). A gap or space in theadhesive layer 46 adjacent one end or other portion of the substrates 41may serve to create sample well 47, comprising a void between thelayers, the well 47 communicating with one or more sample ports 49 (inthis example, ports 48 a, 48 b in the sides of sensor strip 40).Additional functionalization material 49 (e.g., comprising GOx for anexemplary glucose detector) may be deposited on either or both ofelectrode 42 and/or film 45 in line with sample well 47.

As seen in FIG. 10, View C (detail), a blood sample 11 may be drawn bycapillary action into sample well 47 so as to contact both counterelectrode 42 and film 45, and so as to dissolve associatedfunctionalization 49. A signal (e.g., an electrochemically generatedcurrent) is measured by monitor circuitry 50 (diagrammatically indicatedby a meter), so as to produce a measurement of the glucose concentration(or other target analyte) in sample 11.

Advantageously, the nanotube film 45 may be pre-functionalized or todeposition with nanoscale Pt particles. For example, surface oxidizedSWNTs may be suspended (e.g., with sonification) in a solvent such asethylene glycol-water mixture, containing a selected concentration ofhexachloroplatinic acid Preferably, the pH is adjusted (e.g. with NaOH)to about 13. The solution may be heated to about 140 deg. C. in anoxygen-free atmosphere for an period to permit Pt reduction. The treatedSWNTs may be centrifuged to remove solvent, and re-suspended in adesired deposition solvent prior to applying to substrate 41 b. Theconcentrations of reagents and treatment temperature and time may beadjusted to produce the desired Pt content in the final film.

The conductive nanostructured film electrode 45 preferably comprise afilm of carbon nanotubes, and more preferably comprises a highly-uniformnetwork of SWNTs. In comparison to conventional glucose test strips(e.g., the Freestyle™ system, and others) employing other conductivematerials, the film 45 is configured to provide at least the followingadvantages:

-   -   (a) Accelerated response of sensor 40 to sample 11—film 45        provides a faster electrochemical response signal to reaction        products (e.g., hydrogen peroxide and gluconic acid) from the        enzymatic reaction to the glucose substrate.    -   (b) Film 45 provides a smooth, consistent surface for binding        GOx (or other catalysts or cofactors), so as to produce a test        strip with more consistent response to samples, so as to greatly        reduce system calibration problems, leading to reduced costs,        improved reliability and greater convenience of use.

The inclusion of platinum or Pt (or other metal catalyst) in theconductive nanostructured film electrode 45 is preferably as nanoscaleparticles of a size generally on the order of the diameter of thenanotubes or smaller. In comparison to a film 45 without Ptfunctionalization, the Pt containing; film provide at least thefollowing advantages:

-   -   (a) The Pt nanoparticles provide an even faster electrochemical        response signal to reaction products (e.g., hydrogen peroxide        and gluconic acid).    -   (b) The Pt nanoparticles provide an even better binding point        for immobilizing GOx (or other catalysts or cofactors), so as to        advantageously produce a test strip with more consistent        response to samples.    -   (c) The described process for pre-functionalizing the nanotubes        with Pt (or other metal catalyst) permits convenient fabrication        and a much more advantageous control of Pt particle size,        distribution and content than other methods of applying or        depositing Pt to a previously formed nanotube network, thus        improving the value of (a) and (b) above.

Example F SWNT-PAWS Functionalization

In this exemplary embodiment, the nanotubes are treated with a polymericfunctionalization material. In this novel embodiment, thefunctionalization material includes poly (m-aminobenzene sulfonic acid)or PABS covalently attached to SWNTs (SWNT-PABS). The functionalizednanotubes may be included in any of the suitable sensor embodimentshaving aspects of the invention, such as the sensors described and shownin FIG. 2A, FIGS. 4A-C, and FIG. 10. In this example, thePABS-functionalized nanotubes were included in an electrochemical teststrip generally similar to that shown in FIG. 10.

A composition of SWNT-PABS powder is commercially available from CarbonSolutions, Inc. of Riverside Calif., and may be made as described in BZhao et al, “Synthesis and Properties of a Water-Soluble Single-WalledCarbon Nanotube Poly(m-aminobenzene sulfonic acid) Graft Copolymer”, AdvFunct Mater (2004) Vol 14, No 1 pp 71-76, which article is incorporatedby reference. An aqueous solution of SWNT-PABS may be prepared byultrasonication (e.g., 1 mg/mL). After brief sonication, a homogeneousdispersion of carbon nanotubes was obtained.

The sensor in this example includes a flexible substrate comprising PETsheet (which are commercially available from McMaster-Carr SupplyCompany of Chicago Ill.). The carbon nanotubes dispersion was sprayedwith an air brush in several steps with intermediate drying until thedesired resistance was obtained. In this example, the deposition wascarried out on with the substrate on a hot-plate with the temperature ofabout 75 degree C., and the dispersion was deposited step-wise until thehalf-inch resistance obtained using the pin probe reached a targetresistance (for example, from about 1 to about 15 K Ohm).

The response of the sensors to glucose was demonstrated using the H2O2solution as a simulant to glucose (note that the reaction of GOx withblood glucose produces peroxide, which in turn generates the measurementcurrent). The 2.5 mM H2O2 solution was prepared corresponding to the 400mg/dl of glucose concentration. A meter from Hypogard was used to recordthe reading of the glucose. The meter was calibrated based on theconductivity of CNT film.

The response of PABS-SWNT strip sensor to 400 mg/dl glucose is as shownin FIG. 11. The meter records 367 mg/dl giving less than 10% error inthe measurement of actual glucose concentration. Also the time (<2seconds) required for measurement is less than in a conventional teststrip, demonstrating that the exemplary sensor is a faster sensor for‘glucose detection.

The molecular sensing mechanism of glucose for the SWNT-PABS can beunderstood considering the chemistry of polyaniline (PANI). PANIs areappealing for sensor applications because their electronic propertiescan be reversibly controlled by doping/dedoping at room temperature. Thechemical modification of SWNTs significantly affected the sensitivityand reversibility of the behavior of the sensors. PABS is awater-soluble conducting polymer. The presence of SO3H groups improvedthe solubility and processability of this sulfonated polyanilinederivative, and it is especially attractive for introducing acid-basesensitivity together with a further doping response into sensor devices.

Glucose chemically binds to the benzene sulfonic acid groups, whichgreatly influences the electrochemical activity of the polyanilinebackbone due to steric effects. The carbon nanotubes in the compositenot only increase the effective electrode surface area (therebyincreasing the density of benzene sulfonic acid groups for glucosebinding), they also greatly increase the stability of the film.

In this concept, the conducting polymer (PABS) acts as theimmobilization matrix as well the physio-chemical transducer to converta chemical signal (change of chemical potential of the microenvironment)into an electrical signal. The conducting polymer acts as the electronmediator while the carbon nanotubes provide enhanced surface area. Thesensors in this example may be made from pre-functionalized nanotubes,thus eliminating an additional step to functionalize nanotubes withpolymers. Unlike conventional glucose biosensors, no electrochemicaldeposition is required in this case making it easy-to-fabricate sensorprocess.

Alternative techniques may be employed to functionalize nanotubes withother suitable conductive polymeric materials, such as PANI or may beemployed. See, for example, the electrochemical treatments described inT Zhang et al, “Nanonose: Electrochemically Functionalized Single-WalledCarbon Nanotube Gas Sensor Array”, Proc. 208th Meeting ofElectrochemical Society (Los Angeles, Calif. Oct. 16-21, 2005), which isincorporated by reference. Similarly, different polymer like poly(aniline boronic acid); various functionalized tubes can also be used tofunctionalize CNTs for non-enzymatic glucose detection.

The SWNTs (or alternative nanostructures) functionalized with PABS(other alternative conductive polymers such as other polyanilinederivatives) are advantageously employed to comprise the nanostructuredfilm electrode 45 as shown in FIG. 10. In comparison to conventionalglucose test strips (e.g., the FreeStyle™ system, and others) employingother conductive materials, the film 45 comprising is configured toprovide at least the following advantages:

-   -   (a) The example electrode film 45 having conductive polymer        functionalization (e.g., PARS) provides a faster electrochemical        response signal to reaction products (e.g., hydrogen peroxide        and gluconic acid) from the enzymatic reaction to the glucose        substrate. In addition, where, as in this example, there is a        covalent bend between the conductive polymer (e.g., PABS) and        the conductive nanostructure (e.g., SWNTs), the accelerated        response is particularly notable.    -   (b) The example electrode film 45 having conductive polymer        functionalization provides a smooth, consistent surface for        binding GOx (or other catalysts or cofactors), providing the        advantageous described above with respect to Pt functionalized        nanotube films.    -   (c) In many cases, the example electrode film having conductive        polymer functionalization of this EXAMPLE E provides better        sensor properties and response, in comparison to the alternative        film having Pt functionalization as described in EXAMPLE E    -   (d) An additional alternative electrode film 45 may        advantageously have conductive polymer functionalization in        combination with Pt functionalization. For example, SWNTs (or        other nanostructures) may be pre-functionalized with both PABS        and Pt, and then deposited as a film electrode. In yet other        alternative examples, a film electrode may be deposited from a        mixture of differently-functionalized nanotubes (e.g.        SWNT/PABS+SWNT/Pt); or a film electrode may be deposited in        layers (e.g., stepwise deposition) of differently-functionalized        nanotubes (e.g. SWNT/PABS layered with SWNT/Pt).

Example G Capillary Strip with CNT Working Electrode

FIGS. 12A-12B illustrate an exemplary electrochemical test strip 50having a CNT working electrode 55 and a sample volume 56 communicatingwith a capillary vent 57. Substrate 51 (e.g., PET) supports a pair oftraces 52 a, 52 b which lead sample volume enclosure 56.

The working electrode comprises, for example, a conducting carbon pathwith CNTs deposited on top of it. Traces 52 a, 52 b communicate withworking electrode 55 and counter electrode 58, which are exposed withinsample volume enclosure 56. In this example, sample volume enclosure 56may be formed by a layer of insulating material 53 which serves to:enclose the sides of volume 56; electrically isolate traces 52 a, 52 b,and define a capillary entrance 59 at the tip or margin of strip 50.

The upper bound of sample volume 56 is formed by plate 60 (e.g., a thinplastic piece on the active electrode area using a pressure sensitiveadhesive), which includes a downstream capillary vent 57.

Although trace 52 a and working electrode 55 may be integral,conveniently trance 52 a may comprise screen-printed Ag and electrode 55may comprise printed carbon. A layer including a CNT network isdeposited on the surface of electrode 55. Preferably, trance 52 bcomprises screen-printed Ag and counter/reference electrode 58 comprisesa Ag and AgCl mixture. Traces 52 a, 5211; may alternatively comprisesuitable conductive materials.

An analyte-selective redox enzyme (and suitable cofactors and/ormediators) are deposited on or adjacent working electrode 55.Alternatively or additionally, enzyme and CNTs may be depositedsimultaneously to form the surface layer of electrode 55

A sample, such as a droplet of blood, is applied to entrance 59, whereit moves by capillary forces to fill volume 56. Suitable circuitry (notshown) detects an analyte via a signal transmitted via traces 52 a, 52 b(amperometric, coulometric, or the like).

Carbon Nanotubes (CNTs) Application

Carboxylic acid functionalized CNTs may be suspended in water bysonicating the mixture for about 1 hour or more. The concentration ofCNT may be about 0.1 mg/ml. The concentration and sonication timedepends on the type of CNTs and solvents. The next step is to put thissuspension on the carbon conducting layer to form the working electrode55. For example, this may be performed using the moving head type BioDotinstrument. About 40 nl of the CNT suspension drops may be cast on theelectrode in one cycle of the instrument. This may be repeated withsmall changes in spacing until the desired CNT amount and extent ofcoverage is obtained on the electrode.

Example H Further Improvements and Aspects of the Invention CarbonNanotubes Enabled Improved Accuracy of Biosensors

Biosensors used for monitoring analytes such as glucose in real samplessuch as blood are susceptible to interferences from other species e.g.ascorbic acid, uric acid, other saccharides such as galactose etc.likely to be present in the sample. Additionally, depending on theenzyme and mediator used oxygen dependence could also arise. Hematocrit,which is the amount of red blood cells in the sample may also influencethe glucose measurement. These interfering factors adversely affect theaccuracy of glucose measurement.

Various methods may be employed to increase the accuracy of glucosemonitoring. Using an electro-catalyst such as carbon nanotubes (CNT) tolower the voltage of glucose detection may be used to eliminate some ofthese interferences. In addition the faster reaction may reduce thehematocrit and oxygen sensitivity. Alternatively, hematocrit sensitivitymay be addressed, in particular, by measuring the hematocrit by someother method such as Electrochemical Impedance Spectroscopy (EIS) andinitial glucose concentration by electrochemical measurement and thenestimating the corrected glucose concentration based on these twomeasurements based on a calibration algorithm.

One aspect of the invention includes the use of CNTs to improve thehematocrit estimation using a technique such as EIS and the glucosemeasurement using amperometry/coulometry resulting in an overallaccuracy better than that can be achieved without using CNTs. CNTs havehigh surface area and according to various embodiments have variousfunctionalization chemistries. In combination with a suitableenzyme-mediator system CNTs provide a highly accurate sensor in thefollowing way:

-   -   Various parameters such as phase shift and impedance can be        measured for determining the hematocrit levels at one or        different frequencies of the AC waveforms varying in voltage,        set up for the particular enzyme-mediator system.    -   The hematocrit estimation can be done by AC measurement while        the glucose detection may be performed at a fixed potential.    -   For an effective measurement of hematocrit it is useful to have        a good dependence of phase shift and or magnitude of impedance        on hematocrit concentration.    -   It is also desirable to have as accurate as possible early        glucose estimation at a low potential, which can be further        corrected for hematocrit bias. This depends on the        mediator-enzyme system; in one example, potassium        ferricyanide-glucose oxidase system is at 300 mV vs AgCl or        less.    -   CNT have high surface area and may have various        functionalization chemistries. Different hydrophobic/hydrophilic        behavior is tailored to achieve good hematocrit dependence by        EIS at particular frequencies. This combined with the CNT        enables fast reaction of the mediator. Consequently inherently        low hematocrit dependence results in an insensitivity to a wide        range of hematocrit (packed cell volume) values.    -   CNT-based sensors having a enzyme-mediator chemistry, are        particularly useful for measuring glucose in neonates who have        high hematocrit (55%-65%) concentration and whose hypoglycemic        limit is lower than for adults (40 mg/dl as opposed to 60        mg/dl), wherein high inaccuracies may result using conventional        glucose sensors.

Carbon Nanotubes—FAD-GDH Enzyme Based Sensor

One aspect of the invention provides improved electrochemicalperformance using carbon nanotubes (CNTs) and heme containingdehydrogenase enzymes such as glucose dehydrogenase (GDH) along with asuitable mediator for glucose monitoring.

Advantages of using FAD-GDH include good stability, higher substratespecificity and oxygen insensitivity.

Direct electron transfer between FAD and an electrode using CNTs asmolecular wires provides a mediator-free sensor if desired. Theelectrocatalytic nature of carbon nanotubes provides improvedelectrochemistry—higher current at low potential, higher reversibilityas shown by reduced peak separation, for a redox mediator such aspotassium ferricyanide using CNT. Combining all the advantages of CNTfor the mediator (e.g., ferricyanide), the enzyme with theabove-mentioned advantages of FADGDH provides an excellent biosensorwith the advantages described herein.

Improved Sensor Performance using CNTs with Electro-Catalysts such asMetals

Carbon nanotubes (CNTs) have unique electronic and topologicalproperties. One aspect of the invention provides improvedelectrochemical performance of CNT modified electrodes for variousanalytes such as H₂O₂, Potassium ferricyanide, NADH and as wells asothers such as PQQ, osmium complex etc. Monitoring these compounds isvery important for biosensor applications such as glucose monitoring.This is because these compounds are used as mediators, co-factors oranalytes and are the targets of detection for glucose monitoring. Theanalytical utility of the improved electrochemical performance includes:

-   -   lower applied potentials and higher signal    -   lower interferences    -   better electrode surface morphology—CNTs are nanometer in size        as compared to micron sized carbon particles used in screen        printed electrodes. This along with the electrocatalytic        activity of CNTs generating higher signals enables obtaining a        more reproducible biosensor.    -   better accuracy in the low ranges of glucose concentration    -   more consistent electrochemical responses enabled by better        surface morphology and electrocatalytic activity    -   decreased hematocrit and oxygen dependence    -   direct electron transfer between the enzyme and electrode

Aspects of the invention provide enhancement in the electrochemicalperformance that can be achieved by using CNTs, which can be increasedfurther by using another electro-catalyst such as (but not limited to)metals or metal oxides. Alternative electrocatalyst may includemetals/metal derivatives such as Pt, Pd, Au, Fe₂O₃, and the like whichwill be apparent to ones skilled in the art. Such electro-catalysts canbe deposited on a CNT-modified electrode by techniques such as sputtercoating, electrochemical methods, e.g. by reducing the correspondingmetal salts or simply by suspending the compound in a solvent andcasting it on the electrode to achieve deposition of particles ofvarious dimensions. Alternatively CNTs can be deposited on theelectro-catalyst modified electrode. See for example, U.S. applicationSer. No. 10/945,803 filed Sep. 20, 2004 entitled “Multiple nanoparticleselectrodeposited on nanostructures” (published 2005-0157445), which isincorporated by reference.

The advantages of using the additional electro-catalyst in a CNT-basedsensor include:

-   -   Synergistic effect between CNT and the other electro-catalyst        resulting in performance better than the individual components    -   Commercial availability a low cost of a metal/metal oxide/other        electrocatalyst based electrode and further enhancement can be        realized by combining it with CNT with manufacturing simplicity.    -   Savings in materials cost.    -   The morphology of the electrode can be modified by appropriate        placement of CNTs on the electrode, realizing other advantages        such as faster response, easy diffusion of the analytes, better        stability, reduced leaching for continuous monitoring etc.    -   If other techniques are used for determining the effect of        interferences such as ascorbic acid, hematrocrits, etc. combined        with the electrochemical glucose measurement, improvement can be        realized in those measurements too, the result being better        accuracy.    -   Advantages are realized with various mediator-enzyme systems        depending on the interaction of CNTs and the electrocatalyst        with the system. The systems may be (but not limited to) those        using glucose dehydrogenase-PQQ and NAD dependent, glucose        oxidase and mediators such as ferricyanide, osmium based        mediators and others.

A glucose sensor using CNT with an osmium-based mediator andpyrroloquinoline quinone (PQQ) and glucose dehydrogenase enzyme (GDH)Aspects of the invention provide a biosensor including an osmium polymerbased mediator e.g. osmium poly (pyridyl) derivative and the enzymepyrroloquinoline quinone (PQQ)-glucose dehydrogenase (GDH).

See additional description in U.S. Pat. No. 7,052,591 entitled“Electrodeposition of redox polymers and co-electrodeposition of enzymesby coordinative crosslinking”; and US Patent Publication 2006-0169599entitled “Small Volume In Vitro Analyte Sensor,” each of which areincorporated by reference.

This unique system combines highly desirable attributes of CNTs, PQQ-GDHand osmium complex with the following advantages:

Direct electron transfer between the enzyme and CNT combined with thehighly efficient osmium based mediator.

Very high sensitivity, high signal to noise ratio, lower appliedpotentials and higher signal, lower interferences, better electrodesurface morphology, better accuracy in the low ranges, more consistentelectrochemical responses, decreased hematocrit and oxygen dependence,faster response, reduced calibration code requirements etc. The redoxbehavior of PQQ is improved by CNT The electron transfer ability of theosmium based mediator may be improved by the use of CNTs.

CNTs functionalized with different chemistries and suspended indifferent solvents influence the interaction of CNT with osmium basedmediator and PQQ-GDH, the optimum combination depends on the particularelectrode design, types of ink, method of measurement such asamperometric or coloumetric etc. and may be optimized for manufacturing.

The CNTs may be mixed with the mediator and enzyme or depositedsequentially for manufacturing simplicity—CNT followed by the mediatorfollowed by the enzyme or any combination thereof or the CNTs may becovalently attached to the enzyme using chemistry such as thecarbodiimide chemistry.

Method of Enzyme Immobilization for Sensor Application.

Aspects of the invention provide a method of preparation of a stablesuspension of functionalized carbon nanotubes (CNT) in water aided bysonication, with addition of the enzyme glucose oxidase to thesuspension and deposition of the suspension on a substrate, such as apolymer substrate with screen-printed Ag/AgCl electrodes, so as to forman electrochemical sensor for monitoring of d-glucose in whole blood.

Other alternatives include using an electron transfer mediator such asPt nanoparticles, ferrocence etc. deposited along with the workingelectrode followed by enzyme immobilization. This leads to a multi stepprocess and can contribute to the problem with precision of theelectrodes. Due to the use of hydrophilic CNT functionalization, aqueousdispersion of CNT is convenient. This enables the incorporation ofenzyme in the suspension. This one step process avoids solvents orbinders which are not compatible with enzymes. The new method describedreduces cost and improve precision of measurement.

Advantages of the inventive enzyme immobilization method include singlestep deposition of carbon nanotubes (electrode material) and the enzyme(or other functional biomolecule) on the sensor surface. The enzymeretains its activity and stability after immobilization on theelectrode. In certain embodiments, depositing the biomolecule and carbonnanotubes together in a single step involves PABS-CNT chemistry used forthe functionalization of CNTs.

This method leads to a decrease in the number of steps for the sensorfabrication which improves reproducibility and improves precision in themanufacture of glucose strips on a commercial scale. Other advantagesinclude improved stability of the CNT suspension (due to thebiomolecule-nanotube interaction), reduced mass transport limitation forthe oxidation of enzymatically generated hydrogen peroxide, betterchance of direct electron transfer between the CNT electrode and theenzyme (due to the positioning of CNTs within the tunneling distance ofthe cofactors). This can make the sensor more sensitive, selective andfaster responding.

Various combinations/variables and more general applications that arecovered under this application:

-   -   Types of carbon nanotubes: processed single walled nanotubes        (SWNT) containing carbonaceous and catalyst related impurities        such as the metal/metal oxide and other materials remaining from        manufacturing, carboxylic acid functionalized SWNT, poly        (m-aminobenzene sulfonic acid) or PABS functionalized SWNT and        pristine as well as carboxylic acid functionalized multi-walled        carbon nanotubes (MWNT) can be used along with the enzyme.        Functionalization chemistries may be used to facilitate        solubilization of the CNTs in water. These include carboxylic        acid, PABS, and other hydrophilic chemistries. In other        embodiments, pristine (no functionalization) SWNTs and MWNTs are        used. Using pristine nanotubes in embodiments wherein attachment        of the biomolecule alone is sufficient to solubilize the        nanotubes simplifies the manufacturing process. For example,        proteins such as streptavidin, different antibodies or antibody        fragments, peptides, glycans, carbohydrates, aptamers, nucleic        acids—example single stranded deoxyribonucleic acid (DNA) may be        sonicated with pristine nanotubes to prepare the suspension. In        other embodiments, a solubilization chemistry is necessary to        achieve desired suspension.    -   Process of preparing the suspension: In certain embodiments, the        methods involve sonication of the (CNT+enzyme) together. In        other embodiments, the methods involve sonication of CNT first,        and the enzyme added later (for example, if prolonged sonication        causes the enzyme to denature) with or without further        sonication to disperse the biomolecule. In other embodiments,        the CNT is suspended in a suitable buffer, for example, if the        enzyme will denature in water. In certain embodiments, one or        more other forms of mixing, stirring, vortexing etc. may be used        in addition to or instead of sonication.    -   Immobilization method for the mixture—using BioDot's BioJet Plus        instrument (moving head type): using the BioJet (spray) along        with shadow mask to cover appropriate areas; using the BioDot        option (drop casting). Other methods include screen printing,        piezoelectric methods and dip coating.    -   Types of biomolecules: as indicated above, the functionalized        biomolecule is attached to the CNTs to interact with the        analyte. In addition to enzymes (with or without mediators) that        interact with glucose (e.g., glucose oxidase), this method is        applicable to various enzymes such as horseradish peroxidase and        other oxido-reductase enzymes for incorporation in sensing        devices. Other functional biomolecules that may be immobilized        using the methods described herein include antibodies and        nucleic acids. Specific examples include proteins such as        streptavidin, different antibodies or antibody fragments,        peptides, aptamers, DNA and RNA    -   Different feature sizes (width, pitch and thickness) of the        electrodes which determine the microstructure of the conducting        paths can be fabricated using the method described here.    -   Various substrates for deposition—Polyethylene terephthalate,        polyimide, alumina ceramic, polycarbonate etc.    -   In certain embodiments, there may be a silver contact layer        underneath the CNT layer.    -   According to various embodiments, the methods may be used to        make sensors as described above, e.g., with a 2 or 3 electrode        configuration (a separate counter electrode or not).    -   In depositing the CNT-biomolecule, the CNTs may be randomly        sprayed or aligned.

During sonication, the biomolecules attach to the CNTs, therebysolubilizing them and allowing them to form a stable solution that maybe deposited on the electrode surface. Without solubilization, thehydrophobic CNTs are not suspended within the solution and will settledown at the bottom of the vial or other container. By attaching thebiomolecules the CNTs disperse throughout the solution, ready fordeposition on the electrode surface. Depending on the particularbiomolecule, attachment may involve non-covalent interaction, covalentbonding, hydrophobic interaction, and It stacking. For example, DNAattaches to the nanotubes via n bonding. Proteins such as bovine serumalbumin (BSA), streptavidin, glucose oxidase, etc. attach vianon-covalent electrostatic/hydrophobic interaction with the nanotubes.In this manner, the CNTs are solubilized and bio-functionalized forinteraction with the analyte in a single step. The resulting suspensionis stable, i.e., the CNTs do not fall out of the suspension. Suspensionsof enzyme-CNT conjugates have been demonstrated to be stable for atleast up to a week. The CNT-biomolecule conjugates remain intact duringthe deposition onto the electrode, providing bio-functionalized CNTs onthe electrode.

In certain embodiments, a separation operation (e.g., centrifugation,decantation, dialysis, filtration, gel chromatography) is performedbetween the sonication and deposition operations, to separate unattachedand loosely attached biomolecules and CNTs from the stable suspension.In other embodiments, no separation operation is required or performedbetween these operations, further simplifying the method. Relatively lowconcentrations of CNTs facilitate the suspension being deposition-readyafter sonication; in certain embodiments, the concentration of CNTs insolution is between about 0.01 mg/ml-1 mg/ml, or 0.1-1 mg/ml, e.g., 0.1mg/ml.

Application of disposable sensors for self monitoring of glucose isimportant due to the frequent use of strips required and the growingnumber of diabetics. The greater control of surface morphology affordedby the use of nanotubes combined with the one step process of enzymeimmobilization could significantly improve the precision of theelectrodes manufactured on a commercial scale. The one step processcould also lead to an easier fabrication process and save manufacturingcosts. Improved sensitivity, a faster response, and selectivity againstinterferences such as due to ascorbic acid, uric acid could lead togreatly improved and consistent performance at a lower cost.

Reduced Oxygen and Hematocrit Bias for Glucose Sensors Using CarbonNanotubes

Variation in response due to the change in the levels of hematocrit andoxygen is an important consideration for biosensors used to monitorsubstances in whole blood such as sensors for glucose monitoring. Thisis not well understood in the prior art, see US Patent Application2004-0079,653 entitled “Biosensor having improved hematocrit and oxygenbiases”, which is incorporated by reference.

Hematocrit bias can be caused by a variety of factors, system specific,such as:

-   -   Volume exclusion—higher level of hematocrit, artificially lower        sensor response    -   Decreased diffusion of the analyte    -   Increased solution resistance    -   A reaction going to completion utilizing all the analyte in the        sample, decreases hematocrit sensitivity    -   Slow reaction rate of the mediator may be responsible for        significant hematocrit sensitivity.

Oxygen bias (capillary, venous, arterial blood sample) is caused for thefollowing reasons:

-   -   For enzymes such as glucose oxidase—oxygen is a co-substrate    -   For enzymes such as glucose dehydrogenase (GDH), which are not        oxygen dependent, this bias can be caused by the slow mediator        reaction. The slow reaction increases the susceptibility of the        intermediates to oxygen quenching. It depends on the type of        enzyme and mediator.

Aspects of the invention include embodiments in which catalytic activityand greatly improved electrochemical behavior of carbon nanotubesprovides advantages for important compounds including hydrogen peroxideand redox mediators such as potassium ferricyanide. The faster electrontransfer and redox behavior of these molecules with CNT provides amethod of improved hematocrit and oxygen bias reduction using CNT forsensors, such as using nicotinamide adenine dinucleotide (NAD′),pyrroloquinoline quinone (PQQ), as the cofactors/coenzymes or having anactive site such as FAD and various mediators such as osmium complex,1,10-phenanthroline quinone (PQ), potassium ferricyanide or others.

In addition the porous structure of CNT film and its interaction withthe enzyme may improve the diffusion of the analyte to the enzyme andthe electrical communication between the enzyme cofactor and theelectrode further reducing the hematocrit and oxygen bias.

EXPERIMENTAL

The following provides details illustrating aspects of the presentinvention. These experimental examples are provided to exemplify andmore clearly illustrate these aspects of the invention and are in no wayintended to be limiting.

Another advantage to the CNT sensors described above over conventional(non-CNT) sensors is reduced sensor-to-sensor variation. The below tablecontains data showing reduced variation (as indicated by lowercoefficient of variation (% CV)) with CNTs deposited on screen printedelectrodes. Method of analysis was based on capacitance measurement inPBS by alternating current (AC) techniques.

CNT sensors, n = 20 Formulation Formulation Formulation Control, n = 20A B C Average (F) 9.29E−09 4.20E−06 5.18E−06 4.26E−06 SD 2.83E−108.03E−08 6.42E−08 5.80E−08 CV % 3.05% 1.91% 1.24% 1.36%The control sensor was sensor without CNTs. As can be seen, thevariation across the 20 sensors is less than 2% for each of the CNTsensors, as compared to over 3% for the control.

FIG. 13 shows cyclic voltammmetry data with 10 mM potassium ferricyanidefor strips having CNT-functionalized conductive carbon layer and stripshaving a conductive carbon layer without CNTs. (Supportingelectrolyte-50 mM pH 7.4 phosphate buffer+0.1 m KCl, scan rate 100mV/sec, 10 mM potassium ferricyanide. Experimental set up—Cyclicvoltammetry (CV) with standard three electrode electrochemical cell,Working electrode—screen printed electrode with and without CNTfunctionalization, Ag/AgCL reference electrode, Pt wire counterelectrode.)

No electrochemical signal is recorded for control strips without CNTs.(1301 shows ferricyanide at CNT-SPE (carbon nanotube-screen printedelectrode); 1303 shows CNT-SPE alone; and 1305 shows ferricyanide (noCNTs). FIG. 13 shows that highly enhanced electrochemical performance isobtained with CNT functionalized conductive carbon layer.

FIG. 14A shows glucose detection in blood spiked with variousconcentrations of glucose using glucose oxidase enzyme and potassiumferricyanide mediator with a CNTs modified electrode. Potential 300 mVvs. Ag/AgCl.

FIG. 14B shows glucose detection in PBS spiked with variousconcentrations of glucose using glucose oxidase enzyme and potassiumferricyanide mediator. Potential 300 mV vs. Ag/AgCl. Enhancedelectrochemistry does not increase background as seen by low signal forinterfering species (ascorbic acid, acetaminophen) compared to glucose.No signal obtained without CNTs on these electrodes.

FIGS. 15A and 15B show that antibodies used to suspend pristine CNTsretain their functionality. 3 μL of 0.33 mg/mL pristine CNTs+1.5 mg/mLanti-Horseradish Peroxidase (HRP) antibody suspended in water bysonication for 60 min dropcast on a screen printed carbon electrode.Screen printed AgCl electrode was the reference electrode. Theelectrodes were treated with Starting Block solution from Pierce for 1hr at room temperature to prevent non specific adsorption of thereporter HRP. For background data the bare carbon electrodes were usedafter blocking by a similar procedure. The reporter solution was 167ng/mL anti Human chorionic gonadotropin ahCG-HRP (dilution from stock instarting block). FIG. 15A shows the electrochemical signal for thebackground and aHRP antibody-functionalized CNTs. The electrochemicalsignal was obtained by adding 2 ml TMBB (10% Dimethyl Sulfoxide inPhosphate Citrate Buffer+417 nM 3,3,5-tetramethyl-benzidine+10 mM NaCl)and 20.0 uL 250 mM hydrogen peroxide. Applied potential was 150 mV.

3 uL of 0.1 mg/mL pristine CNTs+0.1 mg/mL anti-streptavidin (SAv)antibody suspended in water by sonication for 60 min dropcast on ascreen printed carbon electrode. Screen printed AgCl electrode was thereference electrode. The electrodes were treated with Starting Blocksolution from Pierce for 1 hr at room temperature to prevent nonspecific adsorption of the reporter SAv-HRP. For background data thebare carbon electrodes were used after blocking by a similar procedure.The reporter solution was 500 ng/mL SAv-HRP. The electrochemical signalwas obtained by adding 2 ml TMBB (10% Dimethyl Sulfoxide in PhosphateCitrate Buffer+417 nM 3,3,5-tetramethyl-benzidine+10 mM NaCl) and 20.0uL, 250 mM hydrogen peroxide. Applied potential was 150 mV. Results areshown in FIG. 15B.

1. A method of immobilizing a biomolecule for sensing a target specieson a substrate to fabricate a nanosensor device for sensing the targetspecies, said method comprising: providing a plurality of carbonnanotubes and a quantity of a biomolecule configured to interact withthe target species in an aqueous solution; dispersing the plurality ofnanotubes and at least some of the quantity of the biomolecule tothereby create a stable suspension of nanotubes and biomolecules in theaqueous solution; providing a substrate surface having an electrodesurface thereon; and simultaneously depositing nanotubes andbiomolecules from the stable suspension to at least the electrodesurface to thereby immobilize the biomolecules on the substrate.
 2. Themethod of claim 1 wherein the immobilized biomolecules retain biologicalactivity and stability.
 3. The method of claim 1 wherein the biomoleculeis an enzyme, antibody or nucleic acid.
 4. The method of claim 1 whereinthe biomolecule is configured to interact with glucose.
 5. The method ofclaim 4 wherein the biomolecule is selected from the group consisting ofglucose oxidase, PQQ-GDH and FAD-GDH.
 6. The method of claim 1 whereinthe plurality of carbon nanotubes to be dispersed are pristine.
 7. Themethod of claim 1 wherein the plurality of carbon nanotubes arefunctionalized with a solubilizing chemistry.
 8. The method of claim 7wherein the solubilizing agent is selected from PABS and carboxylic acidgroups.
 9. The method of claim 1 wherein the nanotubes are single wallednanotubes.
 10. The method of claim 1 wherein the nanotubes aremulti-walled.
 11. The method of claim 1 wherein dispersing the nanotubesand at least some of the quantity of biomolecule comprises sonicatingthe aqueous solution.
 12. The method of claim 1 wherein dispersing thenanotubes and at least some of the quantity of biomolecule comprisessonicating the nanotubes in the aqueous solution prior to adding thequantity of biomolecule to the solution.
 13. The method of claim 1wherein depositing nanotubes having biomolecules comprises drop casting.14. The method of claim 1 wherein the quantity of biomolecule configuredto interact with the target species comprises a biomolecule and amediator.
 15. The method of claim 1 wherein the concentration ofnanotubes in the aqueous solution is between about 0.1-1 mg/ml.
 16. Themethod of claim 1 wherein the concentration of nanotubes in the aqueoussolution is about 0.1 mg/ml.
 17. The method of claim 1 wherein noseparation operations are performed between the dispersing anddepositing operations.
 18. The method of claim 1 further comprisingseparating unattached or loosely attached biomolecules and carbonnanotubes from the suspension prior to deposition.
 19. The method ofclaim 1 wherein immobilizing the biomolecule to the substrate is donewithout the use of a binding agent.
 20. A nanoelectronic sensor forglucose detection comprising: a non-conductive substrate; a counterelectrode and working electrode on said substrate, said workingelectrode comprising a carbon conductive path and having a surfacecomprising a carbon nanotube network; a glucose-selective redox enzymeand a mediator in contact with said carbon nanotube network; a samplewell configured for receiving a sample and contacting said sample withthe glucose-selective redox enzyme.
 21. The sensor of claim 20 whereinthe glucose-selective redox enzyme is selected from glucose oxidase,PQQ-GDH and FAD-GDH.
 22. The sensor of claim 20 wherein the mediator isselected from an osmium polymer based mediator and potassiumferricyanide.
 23. The sensor of claim 20 further comprising a metalcatalyst deposited on the carbon nanotube network.